Planarizing build surfaces in three-dimensional printing

ABSTRACT

A technique for planarizing build surfaces in three-dimensional printing includes the use of a three-dimensional printer having an extruder with a sensor mechanically coupled thereto, where the sensor is operable to sense a contact force between the extruder and a separate structure. In particular, the sensor may be used to measure the contact force at a plurality of locations across a build surface of the separate structure, so that a difference between the measured contact force at two or more locations can be identified. In response to the difference between the measured contact force at these locations, a control signal may be created to reduce the difference for planarizing the build surface, e.g., by fabricating a layer on the build surface that mitigates irregularities therein, by gap filling on the build surface, or by adjusting a parameter of the three-dimensional printer.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/922,267 filed Oct. 26, 2015, which is a continuation of U.S. patentapplication Ser. No. 14/065,516 filed Oct. 29, 2013 (now U.S. Pat. No.9,168,698), which claims the benefit of U.S. Pat. App. 61/719,874 filedOct. 29, 2012, where the entirety of each of the foregoing is herebyincorporated by reference herein.

BACKGROUND

Three-dimensional printers can be used to fabricate various desiredobjects based on computer models of those objects. However, componentsof the three-dimensional printer may degrade with time—i.e., becomedented, warped, misaligned, etc. These errors may disadvantageouslyaffect the ability of the three-dimensional printer to accuratelyfabricate objects. There remains a need for pressure-sensing extrudersand methods for using same.

SUMMARY

An extruder or other tool head of a three-dimensional printer isinstrumented to detect contact force against the extruder, such as by abuild platform or an object being fabricated. The tool head may also beinstrumented to detect deflection forces and the like acting on the toolthat might indicate an operating error. The resulting feedback data canbe used in a variety of ways to control operation of thethree-dimensional printer during fabrication or diagnostics.

BRIEF DESCRIPTION OF THE FIGURES

The invention and the following detailed description of certainembodiments thereof may be understood by reference to the followingfigures:

FIG. 1 is a block diagram of a three-dimensional printer.

FIG. 2 shows a three-dimensional printer.

FIG. 3 is a block diagram of a fabrication tool for use in athree-dimensional printer.

FIG. 4 is a flowchart of a process for using an instrumented fabricationtool.

FIG. 5 shows a cross section of a leveling operation.

FIG. 6 is a flowchart of a process for fabricating an object.

DETAILED DESCRIPTION

All documents mentioned herein are hereby incorporated in their entiretyby reference. References to items in the singular should be understoodto include items in the plural, and vice versa, unless explicitly statedotherwise or clear from the text. Grammatical conjunctions are intendedto express any and all disjunctive and conjunctive combinations ofconjoined clauses, sentences, words, and the like, unless otherwisestated or clear from the context. Thus the term “or” should generally beunderstood to mean “and/or” and so forth.

The following description emphasizes three-dimensional printers usingfused deposition modeling or similar techniques where a bead of materialis extruded in a layered series of two dimensional patterns as “roads,”“paths” or the like to form a three-dimensional object from a digitalmodel. It will be understood, however, that numerous additivefabrication techniques are known in the art including without limitationmultijet printing, stereolithography, Digital Light Processor (“DLP”)three-dimensional printing, selective laser sintering, and so forth.Such techniques may benefit from the systems and methods describedbelow, and all such printing technologies are intended to fall withinthe scope of this disclosure, and within the scope of terms such as“printer”, “three-dimensional printer”, “fabrication system”, and soforth, unless a more specific meaning is explicitly provided orotherwise clear from the context.

FIG. 1 is a block diagram of a three-dimensional printer. In general,the printer 100 may include a build platform 102, an extruder 106, anx-y-z positioning assembly 108, and a controller 110 that cooperate tofabricate an object 112 within a working volume 114 of the printer 100.

The build platform 102 may include a surface 116 that is rigid andsubstantially planar. The surface 116 may provide a fixed, dimensionallyand positionally stable platform on which to build the object 112. Thebuild platform 102 may include a thermal element 130 that controls thetemperature of the build platform 102 through one or more active devices132, such as resistive elements that convert electrical current intoheat, Peltier effect devices that can create a heating or coolingaffect, or any other thermoelectric heating and/or cooling devices. Thethermal element 130 may be coupled in a communicating relationship withthe controller 110 in order for the controller 110 to controllablyimpart heat to or remove heat from the surface 116 of the build platform102.

The extruder 106 may include a chamber 122 in an interior thereof toreceive a build material. The build material may, for example, includeacrylonitrile butadiene styrene (“ABS”), high-density polyethylene(“HDPL”), polylactic acid (“PLA”), or any other suitable plastic,thermoplastic, or other material that can usefully be extruded to form athree-dimensional object. The extruder 106 may include an extrusion tip124 or other opening that includes an exit port with a circular, oval,slotted or other cross-sectional profile that extrudes build material ina desired cross-sectional shape.

The extruder 106 may include a heater 126 (also referred to as a heatingelement) to melt thermoplastic or other meltable build materials withinthe chamber 122 for extrusion through an extrusion tip 124 in liquidform. While illustrated in block form, it will be understood that theheater 126 may include, e.g., coils of resistive wire wrapped about theextruder 106, one or more heating blocks with resistive elements to heatthe extruder 106 with applied current, an inductive heater, or any otherarrangement of heating elements suitable for creating heat within thechamber 122 sufficient to melt the build material for extrusion. Theextruder 106 may also or instead include a motor 128 or the like to pushthe build material into the chamber 122 and/or through the extrusion tip124.

In general operation (and by way of example rather than limitation), abuild material such as ABS plastic in filament form may be fed into thechamber 122 from a spool or the like by the motor 128, melted by theheater 126, and extruded from the extrusion tip 124. By controlling arate of the motor 128, the temperature of the heater 126, and/or otherprocess parameters, the build material may be extruded at a controlledvolumetric rate. It will be understood that a variety of techniques mayalso or instead be employed to deliver build material at a controlledvolumetric rate, which may depend upon the type of build material, thevolumetric rate desired, and any other factors. All such techniques thatmight be suitably adapted to delivery of build material for fabricationof a three-dimensional object are intended to fall within the scope ofthis disclosure.

The x-y-z positioning assembly 108 may generally be adapted tothree-dimensionally position the extruder 106 and the extrusion tip 124within the working volume 114. Thus by controlling the volumetric rateof delivery for the build material and the x, y, z position of theextrusion tip 124, the object 112 may be fabricated in three dimensionsby depositing successive layers of material in two-dimensional patternsderived, for example, from cross-sections of a computer model or othercomputerized representation of the object 112. A variety of arrangementsand techniques are known in the art to achieve controlled linearmovement along one or more axes. The x-y-z positioning assembly 108 may,for example, include a number of stepper motors 109 to independentlycontrol a position of the extruder 106 within the working volume alongeach of an x-axis, a y-axis, and a z-axis. More generally, the x-y-zpositioning assembly 108 may include without limitation variouscombinations of stepper motors, encoded DC motors, gears, belts,pulleys, worm gears, threads, and so forth. For example, in one aspectthe build platform 102 may be coupled to one or more threaded rods by athreaded nut so that the threaded rods can be rotated to provide z-axispositioning of the build platform 102 relative to the extruder 124. Thisarrangement may advantageously simplify design and improve accuracy bypermitting an x-y positioning mechanism for the extruder 124 to be fixedrelative to a build volume. Any such arrangement suitable forcontrollably positioning the extruder 106 within the working volume 114may be adapted to use with the printer 100 described herein.

In general, this may include moving the extruder 106, or moving thebuild platform 102, or some combination of these. Thus it will beappreciated that any reference to moving an extruder relative to a buildplatform, working volume, or object, is intended to include movement ofthe extruder or movement of the build platform, or both, unless a morespecific meaning is explicitly provided or otherwise clear from thecontext. Still more generally, while an x, y, z coordinate system servesas a convenient basis for positioning within three dimensions, any othercoordinate system or combination of coordinate systems may also orinstead be employed, such as a positional controller and assembly thatoperates according to cylindrical or spherical coordinates.

The controller 110 may be electrically or otherwise coupled in acommunicating relationship with the build platform 102, the x-y-zpositioning assembly 108, and the other various components of theprinter 100. In general, the controller 110 is operable to control thecomponents of the printer 100, such as the build platform 102, the x-y-zpositioning assembly 108, and any other components of the printer 100described herein to fabricate the object 112 from the build material.The controller 110 may include any combination of software and/orprocessing circuitry suitable for controlling the various components ofthe printer 100 described herein including without limitationmicroprocessors, microcontrollers, application-specific integratedcircuits, programmable gate arrays, and any other digital and/or analogcomponents, as well as combinations of the foregoing, along with inputsand outputs for transceiving control signals, drive signals, powersignals, sensor signals, and so forth. In one aspect, this may includecircuitry directly and physically associated with the printer 100 suchas an on-board processor. In another aspect, this may be a processorassociated with a personal computer or other computing device coupled tothe printer 100, e.g., through a wired or wireless connection.Similarly, various functions described herein may be allocated betweenan on-board processor for the printer 100 and a separate computer. Allsuch computing devices and environments are intended to fall within themeaning of the term “controller” or “processor” as used herein, unless adifferent meaning is explicitly provided or otherwise clear from thecontext.

A variety of additional sensors and other components may be usefullyincorporated into the printer 100 described above. These othercomponents are generically depicted as other hardware 134 in FIG. 1, forwhich the positioning and mechanical/electrical interconnections withother elements of the printer 100 will be readily understood andappreciated by one of ordinary skill in the art. The other hardware 134may include a temperature sensor positioned to sense a temperature ofthe surface of the build platform 102, the extruder 126, or any othersystem components. This may, for example, include a thermistor or thelike embedded within or attached below the surface of the build platform102. This may also or instead include an infrared detector or the likedirected at the surface 116 of the build platform 102.

In another aspect, the other hardware 134 may include a sensor to detecta presence of the object 112 at a predetermined location. This mayinclude an optical detector arranged in a beam-breaking configuration tosense the presence of the object 112 at a predetermined location. Thismay also or instead include an imaging device and image processingcircuitry to capture an image of the working volume and to analyze theimage to evaluate a position of the object 112. This sensor may be usedfor example to ensure that the object 112 is removed from the buildplatform 102 prior to beginning a new build on the working surface 116.Thus the sensor may be used to determine whether an object is presentthat should not be, or to detect when an object is absent. The feedbackfrom this sensor may be used by the controller 110 to issue processinginterrupts or otherwise control operation of the printer 100.

The other hardware 134 may also or instead include a heating element(instead of or in addition to the thermal element 130) to heat theworking volume such as a radiant heater or forced hot air heater tomaintain the object 112 at a fixed, elevated temperature throughout abuild, or the other hardware 134 may include a cooling element to coolthe working volume.

FIG. 2 shows a three-dimensional printer. The printer 200 may include acamera 202 and a processor 204. The printer 200 may be configured foraugmented operation using two-dimensional data acquired from the camera202.

The printer 200 may, for example, be any of the three-dimensionalprinters described above.

The camera 202 may be any digital still camera, video camera, or otherimage sensor(s) positioned to capture images of the printer 200, or theworking volume of the printer 200.

The processor 204, which may be an internal processor of the printer200, an additional processor provided for augmented operation ascontemplated herein, a processor of a desktop computer or the likelocally coupled to the printer 200, a server or other processor coupledto the printer 200 through a data network, or any other processor orprocessing circuitry. In general, the processor 204 may be configured tocontrol operation of the printer 200 to fabricate an object from a buildmaterial. The processor 204 may be further configured to adjust aparameter of the printer 200 based upon an analysis of the object in theimage. It should be appreciated that the processor 204 may include anumber of different processors cooperating to perform the stepsdescribed herein, such as where an internal processor of the printer 200controls operation of the printer 200 while a connected processor of adesktop computer performs image processing used to control printparameters.

A variety of parameters may be usefully adjusted during a fabricationprocess. For example, the parameter may be a temperature of the workingvolume. This temperature may be increased or decreased based upon, e.g.,an analysis of road dimensions (e.g. height and width of line ofdeposited build material), or the temperature may be adjusted accordingto a dimensional stability of a partially fabricated object. Thus, wheresagging or other variations from an intended shape are detected, thetemperature may be decreased. Similarly, where cooling-induced warpingor separation of layers is detected, the temperature may be increased.The working volume temperature may be controlled using a variety oftechniques such as with active heating elements and/or use of heated orcooled air circulating through the working volume.

Another parameter that may be usefully controlled according to thecamera image is the temperature of a build platform in the workingvolume. For example, the camera 202 may capture an image of a raft orother base layer for a fabrication, or a first layer of the fabricatedobject, and may identify defects such as improper spacing betweenadjacent lines of build material or separation of the initial layer fromthe build platform. The temperature of the build platform may in suchcases be heated in order to alleviate cooling-induced warping of thefabricated object at the object-platform interface.

Another parameter that may be usefully controlled according to ananalysis of the camera image is the extrusion temperature of anextruder. By heating or cooling the extruder, the viscosity of a buildmaterial may be adjusted in order to achieve a desired materialdeposition rate and shape, as well as appropriate adhesion to underlyinglayers of build material. Where roads of material deviate from apredetermined cross-sectional shape, or otherwise contain visibledefects, the extrusion temperature of the extruder may be adjusted tocompensate for such defects.

Similarly, the parameter may be an extrusion rate of a build materialfrom the extruder. By controlling a drive motor or other hardware thatforces build material through the extruder, the volumetric rate ofmaterial delivery may be controlled, such as to reduce gaps betweenadjacent lines of build material, or to reduce bulges due to excessbuild material.

In another aspect, the parameter may be a viscosity of build material,which may be controlled, e.g., by controlling the extruder temperatureor any other controllable element that can transfer heat to and frombuild material as it passes through the extruder. It will be understoodthat temperature control is one technique for controlling viscosity, butother techniques are known and may be suitable employed, such as byselectively delivering a solvent or the like into the path of the buildmaterial in order to control thermal characteristics of the buildmaterial.

Another parameter that may be usefully controlled is a movement speed ofthe extruder during an extrusion. By changing the rate of travel of theextruder, other properties of the build (e.g., road thickness, spatialrate of material delivery, and so forth) may be controlled in responseto images captured by the camera 202 and analyzed by the processor 204.

In another aspect, the parameter may be a layer height. By controllingthe z-positioning hardware of the printer 200, the layer height may bedynamically adjusted during a build.

The printer may include a memory 208, such as a local memory or a remotestorage device, that stores a log of data for an object being fabricatedincluding without limitation a value or one or more of the parametersdescribed above, or any other data relating to a print. The memory 208may also or instead store a log of data aggregated from a number offabrications of a particular object, which may include data from theprinter 200 and/or data from a number of other three-dimensionalprinters.

A second processor 210, such as a processor on a server or other remoteprocessing resource, may be configured to analyze the log of data in thememory 208 to identify a feature of the object that is difficult toprint. For example, where a corner, overhang, or the like consistentlyfails, this may be identified by analysis of the log of data,particularly where such failures can be automatically detected basedupon analysis of images from the camera 202. Such failures may be loggedin any suitable manner including quantitatively as data characterizingthe failure (based upon image analysis), metadata (e.g., percentcompletion, build parameters, and so forth) and/or a simple failureflag, which may be accompanied by an image of the failed build. In thismanner, the second processor 210 can identify features that should beavoided in printable models, and/or objects that are generally difficultor impossible to print. The second processor 210 may also or instead beconfigured to analyze the results of variations in one or more of theparameters described above. It will be understood that, while the secondprocessor 210 may be usefully located on a remote processing resourcesuch as a server, the second processor 210 may also be the same as theprocessor 204, with logging and related analysis performed locally bythe printer 200 or a locally coupled computer.

The printer 200 may optionally include a display 212 configured todisplay a view of the working volume. The display 212, which may obtainimages of the working volume from the camera 202 or any other suitableimaging hardware, may be configured, e.g., by the processor 204, tosuperimpose thermal data onto the view of the working volume. This may,for example, include thermistor data or data from other temperaturesensors or similar instrumentation on the printer 200. For example, theprinter 200 may include sensors for measuring a temperature of at leastone of the extruder, the object, the build material, the working volume,an ambient temperature outside the working volume, and a build platformwithin the working volume. These and any similar instrumentation may beused to obtain thermal data correlated to specific or general regionswithin and without the printer 200. Where the camera 202 includes aninfrared camera, the thermal data may also or instead include aninfrared image, or a thermal image derived from such an infrared image.

The display 212 may serve other useful purposes. For example, the viewfrom the camera 202 may be presented in the display. The processor 204may be configured to render an image of a three-dimensional model usedto fabricate an object from the pose of the camera 202. If the camera202 is a fixed camera then the pose may be a predetermined posecorresponding to the camera position and orientation. If the camera 202is a moving camera, the processor 204 may be further programmed todetermine a pose of the camera 202 based upon, e.g., fiducials or known,visually identifiable objects within the working volume such as cornersof a build platform or a tool head, or to determine the pose using datafrom sensors coupled to the camera and/or from any actuators used tomove the camera. The rendered image of the three-dimensional modelrendered from this pose may be superimposed on the view of the workingvolume within the display 212. In this manner, the printer 200 mayprovide a preview of an object based upon a digital three-dimensionalmodel, which preview may be rendered within the display 212 for theprinter, or a user interface of the display, with the as-fabricatedsize, orientation, and so forth. In order to enhance the preview, otherfeatures such as build material color may also be rendered using texturemapping or the like for the rendered image. This may assist a user inselecting build material, scaling, and so forth for an object that is tobe fabricated from a digital model.

In another aspect, the printer 200 may optionally include a sensor 214for capturing three-dimensional data from the object. A variety ofsuitable sensors are known in the art, such as a laser sensor, anacoustical range finding sensor, an x-ray sensor, and a millimeter waveradar system, any of which may be adapted alone or in variouscombinations to capture three-dimensional data. The display 212 may beconfigured to superimpose such three-dimensional data onto the displayof the object within the working volume. In this manner, the processor204 may detect one or more dimensional inaccuracies in the object, suchas by comparison of three-dimensional measurements to a digital modelused to fabricate the object. These may be presented as dimensionalannotations within the display 212, or as color-coded regions (e.g.,yellow for small deviations, red for large deviations, or any othersuitable color scheme) superimposed on the display of the object. Theprocessor 206 may be further configured to show summary data in thedisplay 212 concerning any dimensional inaccuracies detected within theobject.

The sensor 214 may more generally include one or more spatial sensorsconfigured to capture data from the object placed within the workingvolume. The second processor 210 (which may be the processor 204) mayconvert this data into a digital model of the object, and the processor204 may be configured to operate the printer 200 to fabricate ageometrically related object within the working volume based upon thedigital model. In this manner, the printer 200 may be used for directreplication of objects simply by placing an object into the workingvolume, performing a scan to obtain the digital model, removing theobject from the working volume, and then fabricating a replica of theobject based upon the digital model. More generally, any geometricallyrelated shape may be usefully fabricated using similar techniques.

For example, the geometrically related object may be a three-dimensionalcopy of the object, which may be a scaled copy, and/or which may berepeated as many times as desired in a single build subject to spatiallimitations of the working volume and printer 200. In another aspect,the geometrically related object may include material to enclose aportion of the object. In this manner, a container or other enclosurefor the object may be fabricated. In another aspect, the geometricallyrelated object may include a mating surface to the object, e.g., so thatthe fabricated object can be coupled to the original source object. Thismay be particularly useful for fabrication of snap on parts such asaesthetic or functional accessories, or any other objects that might beusefully physically mated to other objects. Similarly, a repair piecefor a broken object may be fabricated with a surface matched to anexposed surface of the broken object, which surface may be glued orotherwise affixed to the broken object to affect a repair.

The processor 204 may obtain the digital model using, e.g., shape frommotion or any other processing technique based upon a sequence oftwo-dimensional images of an object. The multiple images may beobtained, for example, from a plurality of cameras positioned to providecoverage of different surfaces of the object within the working volume.In another aspect, the one or more spatial sensors may include a singlecamera configured to navigate around the working volume, e.g., on atrack or with an articulating arm. Navigating around the working volumemay more generally include circumnavigating the working volume, movingaround and/or within the working volume, and/or changing direction toachieve various poses from a single position. The one or more spatialsensors may also or instead include articulating mirrors that can becontrolled to obtain multiple views of an object from a single camera.

In another aspect, the one or more spatial sensors 214 may includecontrollable lighting that can be used, e.g., to obtain differentshadowed views of an object that can be interpreted to obtainthree-dimensional surface data. The processor 204 (or the secondprocessor 210) may also provide a computer automated design environmentto view and/or modify the digital model so that changes, adjustments,additions, and so forth may be made prior to fabrication.

In another aspect, a tool head 220 of the printer may be usefullysupplemented with a camera 222. The tool head 220 may include any tool,such as an extruder or the like, to fabricate an object in the workingvolume of the printer. In general, the tool head 220 may be spatiallycontrolled by an x-y-z positioning assembly of the printer, and thecamera 222 may be affixed to and moving with the tool head 220. Thecamera 222 may be directed toward the working volume, such as downwardtoward a build platform, and may provide a useful bird's eye view of anobject on the build platform. The processor 204 may be configured toreceive an image from the camera and to provide diagnostic informationfor operation of the three-dimensional printer based upon an analysis ofthe image.

For example, the diagnostic information may include a determination of aposition of the tool head within the working volume. The diagnosticinformation may also or instead include a determination of whether thethree-dimensional printer has effected a color change in build material.The diagnostic information may also or instead include a determinationof whether the three-dimensional printer has effected a change from afirst build material to a second build material. The diagnosticinformation may also or instead include an evaluation of whether a buildmaterial is extruding correctly from the tool head. The diagnosticinformation may also or instead include an evaluation of whether aninfill for the object is being fabricated correctly. In one aspect, thediagnostic information may include the image from the camera, which maybe independently useful as a diagnostic tool.

Where the processor 204 is capable of dynamically modifying toolinstructions, the processor 204 may be configured to dynamicallygenerate a pattern to infill the object based, for example, on anoutline image of the object or previous infilling patterns identified inthe image from the camera.

FIG. 3 is a block diagram of a fabrication tool for use in athree-dimensional printer. The tool 300 may include, for example, anextruder or other tool operable to add build material to an object 304during a build process as generally described above. One or more sensors302 may be mechanically coupled or otherwise included in the fabricationtool 300. Each sensor 302 may be operable to sense a contact forcebetween the fabrication tool 300 and a separate structure, such as theobject 304, the build platform 306, or some other structure.

The sensors 302 may collectively or individually sense the contact forcealong one, two, three, or more pairwise non-parallel axes. For example,a normal force (e.g., instantaneous contact force) between thefabrication tool 300 and the build platform 306 may be sensed; adirection and magnitude of deflection of the tip of the fabrication tool(including displacement and/or force) may be sensed in any positions ordirections, etc. More generally, sensors that are collectively operableto sense any force or displacement of the fabrication tool and separatestructure, or any related properties such as compression or strain, maybe used as sensors 302, so long as the contact force(s) described abovemay be calculated from the sensed physical characteristics.

In some implementations, sensors 302 may include one or more ofcapacitive sensors, optical sensors, potentiometric sensors,piezoelectric sensors, or other electromechanical, electromagnetic(e.g., those relying on inductance, the Hall effect, electromagneticeddy currents, linear variable differential transformers, etc.),acoustical, or other sensors, as well as other sensors or combinationsof the foregoing. Strain gauges are one common sensor used for suchmeasurements, and may be suitably adapted for use with the systems andmethods disclosed herein, such as by affixing one or more strain gaugesto an extruder or other location along a mechanical chain that supportsan extruder in an intended position during fabrication. By using a pairof strain gauges, deflection forces may be isolated from normal force.

Each sensor 302 may be in data communication with a controller 308. Thedata communication may be implemented by any means, including viaphysical connection (e.g., by wire or fiber optic cable) directly to thecontroller 308, indirectly through other components, or wirelessly(e.g., via WiFi signal, infrared signal, acoustic signal, etc.). Eachsensor 302 may be operable to transmit a signal to the controller, suchthat the contact force(s) between the fabrication tool and the separatestructure may be calculated from the collection of sensor signals 302.As described more fully below, the controller 308 may include circuitryfor determining and transmitting, based at least in part on the sensorsignals, a control signal to various actuators or other components ofthe three-dimensional printer to control the three-dimensional printerin a manner responsive to the detected forces.

FIG. 4 is a flowchart for using an instrumented fabrication tool. Inparticular, FIG. 4 shows a technique for mitigating planarirregularities in a build surface such as a build platform or a topsurface of an object being fabricated.

In one aspect, the process 400 may be performed prior to fabricating adesired object so as to planarize as build platform.

As shown in step 402, the process 400 may begin by detecting theplanarity of a surface (e.g., the build platform of a three-dimensionalprinter). This evaluation may be based upon a number of contact forcemeasurements across the surface. It may be expected that for ideal(e.g., perfectly planar) surfaces and a similarly ideal x-y carriage forpositioning a tool, a number of contact force measurements at differentlocations on the surface should be equal. However, it may occur thatsome of these contact force measurements are different from others.

The differences amongst the measured contact forces may be attributed towarping of the surface, physical damage to the surface, (e.g., dents,scratches, etc.), the surface having become skewed or misaligned withrespect to its intended mounting position in the three-dimensionalprinter, or other causes. It will be understood that positionalmeasurements may also or instead be suitably employed to planarize asurface as contemplated herein. In some implementations, the surfacecontact forces may be stored along with corresponding x-y positions onthe surface and used later (e.g., during fabrication) to compensate forthe measured irregularities, as described more fully below.

Other steps may optionally be performed at this point. For example,where the collection of measurements indicates that the surface islevel, but skewed to an x-y plane of a fabrication process, a user alertmay be generated notifying the user that the surface (e.g., a buildplatform) requires leveling. In another aspect, where the collection ofmeasurements indicates gross irregularities that may be difficult toaddress with added built material, an error message may be created andoperation of the three-dimensional printer may be paused or terminated.

As shown in step 404, a layer may be fabricated on the surface thatmitigates one or more irregularities in the surface. In someimplementations, fabricating the layer may include: (a) identifying themaximum contact force (or displacement) measured across the surface; (b)at locations where the contact force was measured, depositing an amountof build material at those locations on the surface proportional to thedeviation of the contact force measured at that location from themaximum contact force; and (c) at locations where the contact force wasnot measured, deriving an estimated contact force by interpolation,regression, multi-dimensional curve fitting, or other mathematicalmodel; and (d) depositing an amount of build material at those locationsproportional to the deviation of the estimated contact force at thatlocation from the maximum contact force. Equivalently, this processinvolves filling in gaps in the surface with build material, so that theresultant layer is effectively planar.

This process 400 may be usefully employed prior to initiating afabrication process in order to ensure a level surface for building.This process 400 may also or instead be used periodically during afabrication process to ensure that a build remains leveled, orcontinuously, e.g., by monitoring contact force and controlling flowrate, to maintain a level top surface of an object during fabrication.

FIG. 5 shows a cross section of a leveling operation, such as theleveling process described above. In general, a surface 500 of a buildplatform (or a top surface of an object being fabricated) may include adent 502, which is subsequently filled with build material to form thelayer 504. Fabrication of additional objects may now be performed on thetop surface of the layer, and any errors that may have been introducedby the dent 502 may be mitigated by the layer 504.

FIG. 6 is a flowchart of a process for fabricating an object.

As shown in step, 602, the process 600 may begin with identifying buildinstructions for fabricating an object. It will be understood that inthis context, the term “identifying” is intended to be construedbroadly, and may include retrieving instructions from storage,generating machine-ready code from a three-dimensional model, ormodifying other machine-ready code prior to fabrication. Regardless ofhow such instructions are identified, a printer may be provided withinstructions that can be executed to fabricate an object.

As shown in step 604, the process 600 may include initiating a buildusing a three-dimensional printer. The three-dimensional printer mayinclude any of the three-dimensional printers described above, and mayfor example include a fabrication tool such as an extruder and one ormore sensors such as strain gauges mechanically coupled to thefabrication tool. The one or more sensors may be configured to detect acurrent contact force between the fabrication tool and the separatestructure, and to provide corresponding data to a controller of thethree-dimensional printer for use during fabrication.

As shown in step 606, a current contact force may be detected. Thecurrent contact force may be used directly as an input to a controlprogram executing on the controller for the three-dimensional printer,or the current contact force may be compared to other data such as aprevious contact force or an expected contact force in order todetermine an appropriate response. It will be appreciated that otherforces may also be sensed and used in feedback systems as contemplatedherein. For example, a deflection force on the fabrication tool may bemeasured, or a positional deflection or displacement may be measured, inorder to determine when adjustments might be made or when a processshould be paused or terminated due to an inferred failure.

As shown in step 608, the process 600 may include creating a controlsignal in response to the current contact force. The control signal maybe generated, e.g., by the controller, to control at least one componentof the three-dimensional printer during a build. For example, thecomponent may be a drive system for a filament of build material orother hardware that controls a feed rate for build material, and thecontrol signal may change the feed rate of build material extruded by anextruder to increase or decrease the current contact force measured bythe sensor(s). In another aspect, the component may be a component thatcontrols a z-axis position of an extruder within a build volume of athree-dimensional printer, e.g., by controlling a distance between theextruder and a build platform (or more generally, between a fabricationtool and a separate structure), and the control signal may vary thedistance to adjust to maintain relatively steady material depositionwhile adjusting to surface irregularities. More generally, thecontroller may adjust to sensed conditions by adjusting any suitableparameter of the three-dimensional printer to obtain an operationaltarget, such as reducing a difference between the current contact forceand an expected contact force or a target contact force.

Where a detected current contact force exceeds some threshold, ordeviates from an expected value by a certain relative or absoluteamount, other actions may be taken. For example, the process 600 mayinclude terminating a build when a difference between the currentcontact force and the expected contact force indicates a fabricationerror.

In another aspect, control data may be incorporated directly intomachine ready code for use during fabrication. For example a buildinstruction in machine-ready code may directly specify a target for thecontact force, e.g., as an explicit instruction to achieve or maintain aspecified contact force between the fabrication tool and a separatestructure. With such an instruction, a control signal may be generatedduring fabrication that controls one or more components of athree-dimensional printer (e.g., components that control feed rate,z-axis position, extrusion head speed, temperature) to achieve thespecified contact force.

In another aspect, the method may include detecting planarity andresponsively making corrections as described above with reference toFIG. 4. This leveling process may be performed prior to or concurrentlywith a fabrication process for an object.

The methods or processes described above, and steps thereof, may berealized in hardware, software, or any combination of these suitable fora particular application. The hardware may include a general-purposecomputer and/or dedicated computing device. The processes may berealized in one or more microprocessors, microcontrollers, embeddedmicrocontrollers, programmable digital signal processors, or otherprogrammable device, along with internal and/or external memory. Theprocesses may also, or instead, be embodied in an application specificintegrated circuit, a programmable gate array, programmable array logic,or any other device or combination of devices that may be configured toprocess electronic signals. It will further be appreciated that one ormore of the processes may be realized as computer executable codecreated using a structured programming language such as C, an objectoriented programming language such as C++, or any other high-level orlow-level programming language (including assembly languages, hardwaredescription languages, and database programming languages andtechnologies) that may be stored, compiled or interpreted to run on oneof the above devices, as well as heterogeneous combinations ofprocessors, processor architectures, or combinations of differenthardware and software.

Thus, in one aspect, each method described above and combinationsthereof may be embodied in computer executable code that, when executingon one or more computing devices, performs the steps thereof. In anotheraspect, the methods may be embodied in systems that perform the stepsthereof, and may be distributed across devices in a number of ways, orall of the functionality may be integrated into a dedicated, standalonedevice or other hardware. In another aspect, means for performing thesteps associated with the processes described above may include any ofthe hardware and/or software described above. All such permutations andcombinations are intended to fall within the scope of the presentdisclosure.

It should further be appreciated that the methods above are provided byway of example. Absent an explicit indication to the contrary, thedisclosed steps may be modified, supplemented, omitted, and/orre-ordered without departing from the scope of this disclosure.

The method steps of the invention(s) described herein are intended toinclude any suitable method of causing such method steps to beperformed, consistent with the patentability of the following claims,unless a different meaning is expressly provided or otherwise clear fromthe context. So for example performing the step of X includes anysuitable method for causing another party such as a remote user or aremote processing resource (e.g., a server or cloud computer) to performthe step of X. Similarly, performing steps X, Y and Z may include anymethod of directing or controlling any combination of such otherindividuals or resources to perform steps X, Y and Z to obtain thebenefit of such steps.

While particular embodiments of the present invention have been shownand described, it will be apparent to those skilled in the art thatvarious changes and modifications in form and details may be madetherein without departing from the spirit and scope of this disclosureand are intended to form a part of the invention as defined by thefollowing claims, which are to be interpreted in the broadest senseallowable by law.

What is claimed is:
 1. A method of planarizing build surfaces inthree-dimensional printing, the method comprising: initiating a buildusing a three-dimensional printer including an extruder and one or moresensors mechanically coupled to the extruder, the one or more sensorsoperable to sense a contact force between the extruder and a separatestructure distinct from the extruder; measuring the contact force at aplurality of locations across a build surface of the separate structureusing the one or more sensors; identifying a difference between themeasured contact force at two or more locations of the plurality oflocations; and creating a control signal to adjust the build in responseto the difference between the measured contact force at the two or morelocations, the control signal configured to reduce the difference forplanarizing the build surface.
 2. The method of claim 1, wherein thecontrol signal includes instructions to fabricate a layer on the buildsurface that mitigates one or more irregularities in the build surface.3. The method of claim 2, further comprising fabricating the layer usingthe three-dimensional printer.
 4. The method of claim 3, whereinfabricating the layer includes: identifying a maximum contact forcemeasured across the build surface; and depositing an amount of buildmaterial at each of the plurality of locations where the contact forcewas measured besides a location of the maximum contact force, the amountof build material proportional to a deviation of measured contact forcefrom the maximum contact force.
 5. The method of claim 4, furthercomprising: deriving an estimated contact force at locations along thebuild surface where contact force was not measured; and depositing buildmaterial at the locations along the build surface where contact forcewas not measured in an amount that is proportional to a deviation of theestimated contact force from the maximum contact force.
 6. The method ofclaim 1, wherein the control signal includes instructions to fill one ormore gaps in the build surface with build material deposited from theextruder.
 7. The method of claim 1, further comprising, based on thecontrol signal, pausing or terminating the build when the differencebetween the measured contact force indicates a fabrication error.
 8. Themethod of claim 1, further comprising storing the measured contact forceat the plurality of locations with corresponding positional informationregarding the plurality of locations.
 9. The method of claim 8, furthercomprising implementing adjustments to the build using the storedmeasured contact force.
 10. The method of claim 1, further comprisinggenerating a notification for sending to a user of the three-dimensionalprinter in response to the difference between the measured contactforce.
 11. The method of claim 10, wherein the notification includes analert that the build surface is nonplanar.
 12. The method of claim 10,wherein the notification includes an error message.
 13. The method ofclaim 1, wherein the separate structure includes an object beingfabricated by the three-dimensional printer.
 14. The method of claim 1,wherein the separate structure includes a build platform of thethree-dimensional printer.
 15. The method of claim 1, wherein thecontact force is a force normal to the build surface.
 16. The method ofclaim 1, wherein the one or more sensors include at least one of astrain gauge, a piezoelectric sensor, a capacitive sensor, an opticalsensor, an electromechanical sensor, an electromagnetic sensor, and anacoustical sensor.
 17. The method of claim 1, wherein the differencebetween the measured contact force indicates one or more of warping ofthe build surface, physical damage to the build surface, and amisalignment of the build surface.
 18. The method of claim 1, whereinthe control signal includes one or more of an adjustment to a z-axisposition of the extruder, an adjustment to a feed rate of build materialextruded by the extruder, and an adjustment to a speed of movement ofthe extruder.
 19. The method of claim 1, wherein adjustments to thebuild based on the control signal are employed prior to initiatingfabrication of an object using the three-dimensional printer.
 20. Themethod of claim 1, wherein adjustments to the build based on the controlsignal are employed subsequent to initiating fabrication of an objectusing the three-dimensional printer.